Gehl Articulated Loader 650, 750, T750 Service Manual 50940441C – PDF DOWNLOAD

Gehl Articulated Loader 650, 750, T750 Service Manual 50940441C – PDF DOWNLOAD

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Gehl Articulated Loader 650, 750, T750 Service Manual 50940441C – PDF DOWNLOAD

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Gehl Articulated Loader 650, 750, T750 Service Manual 50940441C – PDF DOWNLOAD

Gehl 650
Gehl 750
Gehl T750
Mustang 608
Mustang 708
Mustang 708T
Manitou MLA-6
Manitou MLA-7
Manitou MLA-T 516

SAFETY:

Before operating the machine, first read and study the safety information in this manual. Be sure that anyone who operates or works on the machine is familiar with the safety precautions. This includes providing translations of the warnings and instructions for operators who are not fluent in reading English.

• It is essential that operators be thoroughly trained in the safe operation of the machine and load handling. Such training should be presented completely to all new operators and not condensed for those claiming previous experience.• Operators must not be physically or mentally impaired or under the influence of drugs or alcohol. Do not allow minors or unqualified personnel to operate the machine or to be near the machine unless they are properly supervised. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.• Do not use the machine for any application or purpose other than those described in this manual or in manuals supplied with any attachments used with the machine.• Use of the machine is subject to certain hazards that cannot be eliminated by mechanical means but only by exercising intelligence, care, and common sense. Examples of such hazards include but are not limited to: hillside operation, overloading, load instability, poor maintenance, operating too fast for conditions, and using the machine for a purpose for which it was not intended or designed.• Manitou Group always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards. Operators must be alert, however, because some areas cannot be guarded or shielded without preventing or interfering with proper operation.

TABLE OF CONTENTS:

Gehl Articulated Loader 650, 750, T750 Service Manual 50940441C – PDF DOWNLOAD

Table of Contents……………………………………………………………………………………………………………………………………… 3
Introduction………………………………………………………………………………………………………………………………………….. 13
Safety Symbol and Signal Words………………………………………………………………………………………………………………………. 13
Signal Words…………………………………………………………………………………………………………………………………… 13
Legal Notices……………………………………………………………………………………………………………………………………… 13
Software IP……………………………………………………………………………………………………………………………………. 13
Data Privacy…………………………………………………………………………………………………………………………………… 13
Contents and Use of this Manual……………………………………………………………………………………………………………………… 14
Machine Orientation………………………………………………………………………………………………………………………………… 14
Proper Machine Use…………………………………………………………………………………………………………………………………. 14
Model/Serial Numbers……………………………………………………………………………………………………………………………….. 16
Machine Model and Serial Numbers…………………………………………………………………………………………………………………. 16
Component Serial Numbers………………………………………………………………………………………………………………………… 16
Component Identification……………………………………………………………………………………………………………………………. 17
Non-telescopic Machines…………………………………………………………………………………………………………………………. 17
Telescopic Machines…………………………………………………………………………………………………………………………….. 18
Attachments……………………………………………………………………………………………………………………………………….. 19
Using Attachments………………………………………………………………………………………………………………………………….. 19
Fire Extinguisher………………………………………………………………………………………………………………………………….. 20
Manufacturer Information……………………………………………………………………………………………………………………………. 20
Indicator and Operation Symbols……………………………………………………………………………………………………………………… 21
Safety……………………………………………………………………………………………………………………………………………….. 23
Safety Symbol and Signal Words………………………………………………………………………………………………………………………. 23
Safety Alert Symbol…………………………………………………………………………………………………………………………….. 23
Signal Words…………………………………………………………………………………………………………………………………… 23
Mandatory Safety Shutdown Procedure………………………………………………………………………………………………………………….. 24
Before Starting……………………………………………………………………………………………………………………………………. 24
During Operation…………………………………………………………………………………………………………………………………… 26
Provision for Stability/Avoiding Rollover and Tipover Accidents…………………………………………………………………………………………. 28
Telescopic Machines………………………………………………………………………………………………………………………………… 30
Articulated Loader Stability………………………………………………………………………………………………………………………… 30
Effect of Load Arm Lowering on Stability………………………………………………………………………………………………………….. 31
Effect of Load Arm Extension on Stability (Telescopic Machines Only)…………………………………………………………………………………. 31
Effect of Uneven or Unstable Ground on Stability…………………………………………………………………………………………………… 31
Effect of Machine Travel on Stability…………………………………………………………………………………………………………….. 32
Effect of Load Movement on Stability……………………………………………………………………………………………………………… 32
Applications with Load-Handling Devices………………………………………………………………………………………………………………. 32
Parking the Machine………………………………………………………………………………………………………………………………… 33
Electrical Energy………………………………………………………………………………………………………………………………….. 33
Maintenance and Service Safety Practices……………………………………………………………………………………………………………… 33
Battery Hazards……………………………………………………………………………………………………………………………………. 35
Fire Hazards………………………………………………………………………………………………………………………………………. 35
Additional Safety Equipment…………………………………………………………………………………………………………………………. 36
Crystalline Silica Exposure…………………………………………………………………………………………………………………………. 37
Transporting the Machine……………………………………………………………………………………………………………………………. 37
Raising the Machine with a Crane…………………………………………………………………………………………………………………….. 37
Loading and Transporting the Machine…………………………………………………………………………………………………………………. 37
Safety Decals……………………………………………………………………………………………………………………………………… 38
New Decal Application…………………………………………………………………………………………………………………………… 38
Non-Telescopic Machines…………………………………………………………………………………………………………………………. 39
Telescopic Machines…………………………………………………………………………………………………………………………….. 40
ANSI-Style and Common Safety Decal Locations………………………………………………………………………………………………………….. 41
ISO-Style Safety Decal Locations…………………………………………………………………………………………………………………….. 46
Indicators and Controls………………………………………………………………………………………………………………………………… 51
Multi-Function Display……………………………………………………………………………………………………………………………… 53
Multi-Function Display Symbols…………………………………………………………………………………………………………………… 54
Multi-Function Display Screens…………………………………………………………………………………………………………………… 56
Control Keypad…………………………………………………………………………………………………………………………………….. 62
Switch Panel………………………………………………………………………………………………………………………………………. 63
Audible Alerts…………………………………………………………………………………………………………………………………. 64
Telescopic Machines Load/Level Indicators (Telescopic Machines)…………………………………………………………………………………………. 64
Load Arm Angle Indicator (Telescopic Machines)…………………………………………………………………………………………………….. 64
Load Arm Extension Indicator (Domestic Telescopic Machines Only)…………………………………………………………………………………….. 64
Longitudinal Load Moment Indicator (LLMI) (EU Telescopic Machines Only)………………………………………………………………………………. 65
Lateral Level Indicator (Telescopic Machines)……………………………………………………………………………………………………… 65
Ignition Switch……………………………………………………………………………………………………………………………………. 66
Operator’s Seat/Armrest…………………………………………………………………………………………………………………………….. 66
Multi-Function Joystick…………………………………………………………………………………………………………………………….. 67
Load Arm/Attachment Tilt Control…………………………………………………………………………………………………………………. 67
Telescopic Load Arm Extend/Retract Control Switch (Telescopic Machines)………………………………………………………………………………. 67
Non-Telescopic Machines Float Controls……………………………………………………………………………………………………………. 68
Non-Telescopic Machines Load Arm Float Detent Lock Disable (if equipped)………………………………………………………………………….. 68
Telescopic Machines Raise Float Controls………………………………………………………………………………………………………….. 69
Travel Direction Switch…………………………………………………………………………………………………………………………. 69
Travel Speed Range Selection Button………………………………………………………………………………………………………………. 70
Differential Lock Button………………………………………………………………………………………………………………………… 70
Auxiliary Hydraulics Control Switch………………………………………………………………………………………………………………. 71
Parking Brake……………………………………………………………………………………………………………………………………… 71
Parking Brake Adjustment/Service…………………………………………………………………………………………………………………. 71
Control Lever (Option)……………………………………………………………………………………………………………………………… 72
Throttle Controls………………………………………………………………………………………………………………………………….. 72
Travel Controls……………………………………………………………………………………………………………………………………. 73
Travel Direction Switch…………………………………………………………………………………………………………………………. 73
Travel Pedal…………………………………………………………………………………………………………………………………… 73
Brake/Inching Pedal…………………………………………………………………………………………………………………………….. 74
Steering Wheel…………………………………………………………………………………………………………………………………. 74
Steering Column Adjustment…………………………………………………………………………………………………………………… 74
High/Low Travel Speed Selection……………………………………………………………………………………………………………………… 75
Constant Speed (Option)…………………………………………………………………………………………………………………………….. 75
Differential Lock………………………………………………………………………………………………………………………………….. 76
Engine Off Load Arm Lower…………………………………………………………………………………………………………………………… 76
Non-Telescopic Machines…………………………………………………………………………………………………………………………. 76
Telescopic Machines…………………………………………………………………………………………………………………………….. 76
Hydraulics Transport Lock-out……………………………………………………………………………………………………………………….. 76
Attachment Mounting………………………………………………………………………………………………………………………………… 77
Quick Attachment Hitch………………………………………………………………………………………………………………………….. 77
Auxiliary Hydraulic System………………………………………………………………………………………………………………………….. 77
Auxiliary Circuit Pressure Relief………………………………………………………………………………………………………………… 77
Auxiliary Hydraulic Control……………………………………………………………………………………………………………………… 78
Standard-Flow Auxiliary Hydraulics Control…………………………………………………………………………………………………….. 78
2nd Auxiliary Hydraulics Circuit (Option)……………………………………………………………………………………………………… 78
High-Flow Auxiliary Hydraulics Control (Option)………………………………………………………………………………………………… 79
Hydraglide™ Button (Option)…………………………………………………………………………………………………………………………. 79
Cooling Fan Rotation Reversing Button………………………………………………………………………………………………………………… 79
Cab Heat and Air Conditioning (HVAC)…………………………………………………………………………………………………………………. 80
Work Lights Button…………………………………………………………………………………………………………………………………. 80
Load Arm Lights Button (Telescopic Machines Only)……………………………………………………………………………………………………… 81
Beacon (Option)……………………………………………………………………………………………………………………………………. 81
Windshield Wiper/Washer and Defrost………………………………………………………………………………………………………………….. 82
Windshield Wiper Button…………………………………………………………………………………………………………………………. 82
Windshield Washer Button………………………………………………………………………………………………………………………… 82
Washer Fluid Reservoir………………………………………………………………………………………………………………………….. 82
Rear Window/Washer Switch……………………………………………………………………………………………………………………….. 82
Rear Window Defrost Switch………………………………………………………………………………………………………………………. 82
12V Accessory Power Outlet………………………………………………………………………………………………………………………….. 83
External 12V Attachment Power Connections (Option)…………………………………………………………………………………………………….. 83
12V Attachment Power Controls……………………………………………………………………………………………………………………. 83
Front Installation………………………………………………………………………………………………………………………….. 83
Rear Installation…………………………………………………………………………………………………………………………… 83
External 12V Attachment Power Extension Harness……………………………………………………………………………………………………. 84
Battery Disconnect Switch…………………………………………………………………………………………………………………………… 84
Operation…………………………………………………………………………………………………………………………………………….. 85
Operational Checks…………………………………………………………………………………………………………………………………. 85
Pre-Start Checks……………………………………………………………………………………………………………………………….. 85
Checks During Operation…………………………………………………………………………………………………………………………. 86
Parking Checks…………………………………………………………………………………………………………………………………. 86
Before Operation…………………………………………………………………………………………………………………………………… 87
Cab Entry and Exit……………………………………………………………………………………………………………………………… 87
Cab Door (Option)………………………………………………………………………………………………………………………………. 87
Door Prop………………………………………………………………………………………………………………………………….. 88
Cab Window Latches……………………………………………………………………………………………………………………………… 88
Emergency Exit…………………………………………………………………………………………………………………………………. 88
Right Window Stop………………………………………………………………………………………………………………………………. 89
Operator’s Seat Adjustment………………………………………………………………………………………………………………………. 89
Seat/Armrest Forward and Back Horizontal Adjustment…………………………………………………………………………………………….. 89
Seat Back Tilt Adjustment……………………………………………………………………………………………………………………. 90
Optional Deluxe Seat Back Adjustment………………………………………………………………………………………………………….. 90
Armrest Height Adjustment……………………………………………………………………………………………………………………….. 90
Optional Deluxe Seat Left Armrest Adjustment…………………………………………………………………………………………………… 90
Seat Belt…………………………………………………………………………………………………………………………………………. 91
Fastening/Unfastening the Seat Belt………………………………………………………………………………………………………………. 91
Dome Light………………………………………………………………………………………………………………………………………… 91
Starting the Engine………………………………………………………………………………………………………………………………… 92
Cold-Starting………………………………………………………………………………………………………………………………….. 94
After Starting…………………………………………………………………………………………………………………………………. 94
Engine Warm Up…………………………………………………………………………………………………………………………………….. 94
Run-In Period……………………………………………………………………………………………………………………………………… 95
Stopping the Engine………………………………………………………………………………………………………………………………… 95
Engine Stalling……………………………………………………………………………………………………………………………………. 95
Safety Interlock System (Hydraloc™)………………………………………………………………………………………………………………….. 95
Safety Interlock System Test…………………………………………………………………………………………………………………….. 95
Travel Drive Operation……………………………………………………………………………………………………………………………… 96
High/Low and Optional 3-Speed Travel Speed Modes…………………………………………………………………………………………………… 99
High/Low Drive Speed Button………………………………………………………………………………………………………………….. 99
3-Speed Option……………………………………………………………………………………………………………………………… 99
Differential Lock Operation……………………………………………………………………………………………………………………… 99
Constant Speed Operation (Option)…………………………………………………………………………………………………………………….100
Travel Drive Error Condition Operation (Limited and Safe Modes)………………………………………………………………………………………101
Backup Alarm (Option)……………………………………………………………………………………………………………………………101
Special Considerations for Telescopic Machines…………………………………………………………………………………………………………102
Telescopic Load Arm Operation…………………………………………………………………………………………………………………….102
Longitudinal Load Moment Indicator (LLMI) – EU Telescopic Machines Only……………………………………………………………………………….103
Load Arm Operation………………………………………………………………………………………………………………………………….104
Load Arm Travel Position…………………………………………………………………………………………………………………………104
Load Arm/Attachment Tilt Operation………………………………………………………………………………………………………………..105
Engine Off Load Arm Lower (Non-Telescopic Machines)…………………………………………………………………………………………………105
Non-Telescopic Machines Float Operation (Raise and Tilt)…………………………………………………………………………………………….106
Non-Telescopic Machines Load Arm Float Detent Lock Disable Operation (if so equipped)……………………………………………………………….107
Telescopic Machines Raise Float Operation………………………………………………………………………………………………………….107
Load Arm Extend/Retract (Telescopic Machines Only)………………………………………………………………………………………………….108
Load Arm Raise/Tilt Support (Non-Telescopic Machines Only)………………………………………………………………………………………………110
Engage Load Arm Support………………………………………………………………………………………………………………………….110
Disengage Load Arm Support……………………………………………………………………………………………………………………….111
Engage Tilt Support……………………………………………………………………………………………………………………………..112
Disengage Tilt Support…………………………………………………………………………………………………………………………..113
Self-Leveling and Return-To Dig………………………………………………………………………………………………………………………114
Self-Leveling (Load Arm Raise)……………………………………………………………………………………………………………………114
Return to Dig (Load Arm Lower)……………………………………………………………………………………………………………………114
Hydraglide™ Ride Control System (Option)………………………………………………………………………………………………………………114
Hydraulics Transport Lock-Out Operation……………………………………………………………………………………………………………….115
Connecting/Disconnecting Attachments………………………………………………………………………………………………………………….116
Power-A-Tach® System Hitch Operation………………………………………………………………………………………………………………116
Connecting Attachments Using Power-A-Tach® System Hitch………………………………………………………………………………………….116
Disconnecting Attachments Using Power-A- Tach® System Hitch………………………………………………………………………………………117
Euro-Style and 4-Point Hitch Operation…………………………………………………………………………………………………………….118
Connecting Attachments Using Euro-Style and 4-Point Hitches………………………………………………………………………………………118
Disconnecting Attachments Using Euro-Style and 4-Point Hitches……………………………………………………………………………………121
Powering Attachments with Hydraulic Function…………………………………………………………………………………………………………..122
Connecting Hydraulic Attachments to the Auxiliary Hydraulic Circuits………………………………………………………………………………….122
Disconnecting Hydraulic Attachments from the Auxiliary Hydraulics Circuit……………………………………………………………………………..124
Auxiliary Hydraulics Operation……………………………………………………………………………………………………………………124
Standard-Flow Auxiliary Hydraulics Operation……………………………………………………………………………………………………124
2nd Auxiliary Hydraulics Circuit (Option – Non- Telescopic Machines Only)………………………………………………………………………….125
High-Flow Auxiliary Hydraulics Operation……………………………………………………………………………………………………….125
14-Pin Connector (Option)……………………………………………………………………………………………………………………………126
Switch / Pin Assignments…………………………………………………………………………………………………………………………126
Working with Buckets………………………………………………………………………………………………………………………………..127
Digging Tips……………………………………………………………………………………………………………………………………127
Safety Instructions When Working with Buckets………………………………………………………………………………………………………127
Working with Buckets…………………………………………………………………………………………………………………………….128
Scooping……………………………………………………………………………………………………………………………………128
Loading…………………………………………………………………………………………………………………………………….128
Digging…………………………………………………………………………………………………………………………………….128
Grading…………………………………………………………………………………………………………………………………….129
Using Attachment Tilt Float…………………………………………………………………………………………………………………..129
Backfilling…………………………………………………………………………………………………………………………………130
Operating on Hard Surfaces……………………………………………………………………………………………………………………130
Working with Pallet Forks……………………………………………………………………………………………………………………………130
Safety Instructions When Working with Pallet Forks………………………………………………………………………………………………….130
Moving Loads Using Pallet Forks…………………………………………………………………………………………………………………..132
Loading Pallet Forks…………………………………………………………………………………………………………………………132
Raising Loads Using Pallet Forks………………………………………………………………………………………………………………132
Moving Loads Using Pallet Forks……………………………………………………………………………………………………………….133
Setting Down Loads Using Pallet Forks………………………………………………………………………………………………………….133
Diesel Particulate Filter (DPF) Regeneration Procedures…………………………………………………………………………………………………134
Reset Regeneration………………………………………………………………………………………………………………………………134
Reset Regeneration Inhibit……………………………………………………………………………………………………………………134
Stationary Regeneration………………………………………………………………………………………………………………………….135
Forcing Stationary Regeneration……………………………………………………………………………………………………………….136
DPF Maintenance…………………………………………………………………………………………………………………………………137
After Operation…………………………………………………………………………………………………………………………………….137
Jump-Starting………………………………………………………………………………………………………………………………………138
Raising the Machine using a Crane…………………………………………………………………………………………………………………….139
Crane Lifting Preparation………………………………………………………………………………………………………………………..140
Towing…………………………………………………………………………………………………………………………………………….141
Precautions…………………………………………………………………………………………………………………………………….141
Preparation…………………………………………………………………………………………………………………………………….141
Towing Procedure………………………………………………………………………………………………………………………………..142
After Towing……………………………………………………………………………………………………………………………………142
Loading and Transporting the Machine on a Transport Vehicle……………………………………………………………………………………………..143
Loading and Securing the Machine………………………………………………………………………………………………………………….143
Maintenance……………………………………………………………………………………………………………………………………………147
Maintenance Schedule………………………………………………………………………………………………………………………………..149
Checks, Cleaning and Inspection…………………………………………………………………………………………………………………..149
Leakage Check…………………………………………………………………………………………………………………………………..150
Lubrication and Filter Changes……………………………………………………………………………………………………………………151
Functional Check………………………………………………………………………………………………………………………………..151
Maintenance Interval………………………………………………………………………………………………………………………………..152
General Lubrication…………………………………………………………………………………………………………………………………153
Non-Telescopic Machines………………………………………………………………………………………………………………………….153
Telescopic Machines……………………………………………………………………………………………………………………………..154
General Lubrication Detail……………………………………………………………………………………………………………………….155
Telescopic Load Arm Maintenance (Telescopic Machines Only)………………………………………………………………………………………………159
Telescopic Load Arm Section Lubrication……………………………………………………………………………………………………………159
Telescopic Load Arm Wear Pad Replacement…………………………………………………………………………………………………………..160
LLMI Calibration (EU Telescopic Machines Only)…………………………………………………………………………………………………………160
Engine Maintenance………………………………………………………………………………………………………………………………….162
Engine Oil……………………………………………………………………………………………………………………………………..162
Checking Engine Oil Level…………………………………………………………………………………………………………………….162
Changing Engine Oil and Filter………………………………………………………………………………………………………………..163
Engine Air Filters………………………………………………………………………………………………………………………………165
Changing Air Filter Elements……………………………………………………………………………………………………………………..165
Engine Cooling System……………………………………………………………………………………………………………………………166
Checking Coolant Level……………………………………………………………………………………………………………………….166
Cleaning Radiator Fins……………………………………………………………………………………………………………………….167
Draining/Refilling Cooling System……………………………………………………………………………………………………………..167
Belt Maintenance………………………………………………………………………………………………………………………………..169
Checking and Adjusting Belt Tension……………………………………………………………………………………………………………169
DPF Service………………………………………………………………………………………………………………………………………..171
Fuel System Maintenance……………………………………………………………………………………………………………………………..171
Adding Fuel…………………………………………………………………………………………………………………………………….172
Water Separator Inspection/Maintenance…………………………………………………………………………………………………………….172
Changing Fuel Filter…………………………………………………………………………………………………………………………….174
Hydraulic System Maintenance…………………………………………………………………………………………………………………………175
Checking Hydraulic Oil Level……………………………………………………………………………………………………………………..175
Changing Hydraulic Oil…………………………………………………………………………………………………………………………..176
Changing Hydraulic Filter………………………………………………………………………………………………………………………..177
Hydraulic Hose Maintenance…………………………………………………………………………………………………………………………..179
Planetary Axles…………………………………………………………………………………………………………………………………….180
Changing Axle Wheel Hub Oil………………………………………………………………………………………………………………………180
Changing Axle Center Oil…………………………………………………………………………………………………………………………180
Brake Fluid Reservoir……………………………………………………………………………………………………………………………….181
Checking/Replenishing Brake Fluid Reservoir Level…………………………………………………………………………………………………..181
Parking Brake Adjustment/Service……………………………………………………………………………………………………………………..182
Parking Brake Cable Adjustment……………………………………………………………………………………………………………………182
Parking Brake Actuator Bracket Adjustment………………………………………………………………………………………………………….183
Wheels and Tires……………………………………………………………………………………………………………………………………184
Wheel Fasteners…………………………………………………………………………………………………………………………………184
Tires………………………………………………………………………………………………………………………………………….184
Tire Rotation……………………………………………………………………………………………………………………………….184
Checking Tire Pressure……………………………………………………………………………………………………………………….184
Travel Motor Lubrication…………………………………………………………………………………………………………………………….184
Electrical System…………………………………………………………………………………………………………………………………..185
Battery………………………………………………………………………………………………………………………………………..185
Using a Booster Battery (Jump-Starting)……………………………………………………………………………………………………………186
Fuses and Relays………………………………………………………………………………………………………………………………..187
Fuse Box Fuses………………………………………………………………………………………………………………………………187
Fuse Box Relays/Diodes……………………………………………………………………………………………………………………….188
Cooling Fan Control Diode…………………………………………………………………………………………………………………….188
Front Wiper Relay……………………………………………………………………………………………………………………………188
Engine Compartment Relays…………………………………………………………………………………………………………………….189
CAN Resistor……………………………………………………………………………………………………………………………………189
Chassis Grounds…………………………………………………………………………………………………………………………………189
Light Bulb Replacement…………………………………………………………………………………………………………………………..190
Work/Telescopic Load Arm Light Bulb Replacement…………………………………………………………………………………………………190
Tail Light Bulb Replacements………………………………………………………………………………………………………………….190
Headlight Bulb Replacements…………………………………………………………………………………………………………………..191
Dome Light Bulb Replacement…………………………………………………………………………………………………………………..194
14-Pin Connector Fuses, Diodes and Relays (Option)………………………………………………………………………………………………….194
HVAC/Air Conditioning Maintenance…………………………………………………………………………………………………………………….196
HVAC Filters……………………………………………………………………………………………………………………………………196
Cab Air Filters Replacement…………………………………………………………………………………………………………………..196
Air Conditioning Compressor Belt………………………………………………………………………………………………………………….197
Windshield Washer Reservoir………………………………………………………………………………………………………………………….197
Long-Term Storage…………………………………………………………………………………………………………………………………..198
Before Storage………………………………………………………………………………………………………………………………….198
After Storage…………………………………………………………………………………………………………………………………..198
Final Shutdown / Decommissioning……………………………………………………………………………………………………………………..199
Before Disposal…………………………………………………………………………………………………………………………………199
Machine Disposal………………………………………………………………………………………………………………………………..199
Hydrostatic System……………………………………………………………………………………………………………………………………..201
Hydrostatic System General Information………………………………………………………………………………………………………………..201
Charge Pressure Test and Adjustment…………………………………………………………………………………………………………………..204
Preparation…………………………………………………………………………………………………………………………………….204
Test Procedure………………………………………………………………………………………………………………………………….204
Hydrostatic Pump Pressure Relief Valves……………………………………………………………………………………………………………….205
600 Series / MLA-6 Hydrostatic Pump Removal……………………………………………………………………………………………………………206
Splined Coupler Removal/Installation………………………………………………………………………………………………………………….209
600 Series / MLA-6 Hydrostatic Pump Installation……………………………………………………………………………………………………….209
700 Series / MLA-7 / MLA-T Hydrostatic Pump Removal…………………………………………………………………………………………………….213
Splined Coupler Removal/Installation………………………………………………………………………………………………………………….217
700 Series / MLA-7 / MLA-T Hydrostatic Pump Installation………………………………………………………………………………………………..217
Hydrostatic Pump Drive Coupling Removal and Installation………………………………………………………………………………………………..221
Installation……………………………………………………………………………………………………………………………………222
Drive System…………………………………………………………………………………………………………………………………………..225
Drive System General Information……………………………………………………………………………………………………………………..225
Pump and Drive Motor Error Codes……………………………………………………………………………………………………………………..225
Hydraulic Drive Motor……………………………………………………………………………………………………………………………….228
600 Series / MLA-6 Hydraulic Motor Removal…………………………………………………………………………………………………………….230
600 Series / MLA-6 Hydraulic Motor Installation………………………………………………………………………………………………………..232
700 Series / MLA-7 / MLA-T Hydraulic Motor Removal……………………………………………………………………………………………………..235
700 Series / MLA-7 / MLA-T Hydraulic Motor Installation…………………………………………………………………………………………………239
Brake/Inching Pedal Calibration………………………………………………………………………………………………………………………243
Bleeding the Brake System……………………………………………………………………………………………………………………………245
Brake/Inching Pedal Electrical……………………………………………………………………………………………………………………….246
Throttle Pedal Electrical……………………………………………………………………………………………………………………………246
Hand Throttle Electrical…………………………………………………………………………………………………………………………….247
Transmission Control Unit (TCU)/ Drive Controller………………………………………………………………………………………………………247
Travel Drive Control Module Error Codes……………………………………………………………………………………………………………247
Hydrostatic Pump and Drive Motor Error Codes……………………………………………………………………………………………………….249
Hydraulic System……………………………………………………………………………………………………………………………………….251
Hydraulic System General Information………………………………………………………………………………………………………………….251
General Hydraulic Service Notes………………………………………………………………………………………………………………………251
Hydraulic System Diagrams……………………………………………………………………………………………………………………………251
Hydraulic Hoses/Tubes……………………………………………………………………………………………………………………………263
Seals………………………………………………………………………………………………………………………………………….263
Main Pressure Test and Adjustment…………………………………………………………………………………………………………………….264
Control Valve………………………………………………………………………………………………………………………………………266
Main Control Valve Removal……………………………………………………………………………………………………………………….267
Main Control Valve Installation…………………………………………………………………………………………………………………..267
Control Valve Disassembly/Assembly………………………………………………………………………………………………………………..268
Disassembly…………………………………………………………………………………………………………………………………268
Control Valve Assembly……………………………………………………………………………………………………………………….269
Control Valve Solenoid Removal/Installation………………………………………………………………………………………………………..269
Removal…………………………………………………………………………………………………………………………………….269
Installation………………………………………………………………………………………………………………………………..270
Relief Valves Removal and Installation…………………………………………………………………………………………………………….270
Removal…………………………………………………………………………………………………………………………………….270
Installation………………………………………………………………………………………………………………………………..271
Non-Telescopic Machines Tilt/ Lift Cylinder Tests………………………………………………………………………………………………………271
Non-Telescopic Machines Tilt Cylinder Drift Test……………………………………………………………………………………………………271
Non-Telescopic Machines Tilt Cylinder Internal Leakage Test………………………………………………………………………………………….271
Non-Telescopic Machines Lift Cylinder Drift Test……………………………………………………………………………………………………272
Non-Telescopic Machines Lift Cylinder Internal Leakage Test………………………………………………………………………………………….273
Telescopic Machines Lift/Tilt Functional Description……………………………………………………………………………………………………274
Telescopic Load Arm Lift/Tilt Hydraulic Circuit Operation Overview……………………………………………………………………………………274
Telescopic Load Arm Raise Function Overview………………………………………………………………………………………………………..275
Telescopic Load Arm Lower Function Overview………………………………………………………………………………………………………..276
Telescopic Load Arm Hydraglide (Ride Control) Function Overview………………………………………………………………………………………277
Telescopic Load Arm Tilt Self-Level Over-ride………………………………………………………………………………………………………278
Telescopic Machines Tilt/Lift/ Extension Cylinder Tests…………………………………………………………………………………………………279
Telescopic Machines Tilt Cylinder Drift Test……………………………………………………………………………………………………….279
Telescopic Machines Tilt Cylinder Internal Leakage Test……………………………………………………………………………………………..279
Telescopic Machines Lift Cylinder Drift Test……………………………………………………………………………………………………….280
Telescopic Machines Lift Cylinder Internal Leakage Test……………………………………………………………………………………………..280
Telescopic Machines Extension Cylinder Drift Test…………………………………………………………………………………………………..281
Telescopic Machines Extension Cylinder Internal Leakage Test…………………………………………………………………………………………281
Hydraulic Cylinder Disassembly/ Assembly………………………………………………………………………………………………………………282
Cylinder Disassembly…………………………………………………………………………………………………………………………….282
Cylinder Assembly……………………………………………………………………………………………………………………………….282
Bleeding Air After Cylinder Installation…………………………………………………………………………………………………………..282
Hydraulic Solenoid Valves and Tests…………………………………………………………………………………………………………………..283
Cylinder Lower Valve and Test (Non- Telescopic Machines)…………………………………………………………………………………………….283
Isolation Valve (Telescopic Machines)……………………………………………………………………………………………………………..284
Standard Auxiliary Hydraulics Pressure Release Valve and Test………………………………………………………………………………………..284
Machines equipped with standard auxiliary hydraulics only:……………………………………………………………………………………….284
Secondary Auxiliary Hydraulics Pressure Release Valve and Test……………………………………………………………………………………….286
Machines equipped with secondary auxiliary hydraulics only:………………………………………………………………………………………286
High-Flow Auxiliary Hydraulics Valve and Test (Non-Telescopic Machines)……………………………………………………………………………….287
Standard Auxiliary Hydraulics Priority Valve and Test (Telescopic Machines)……………………………………………………………………………289
High-Flow Valve and Test (Telescopic Machines)……………………………………………………………………………………………………..293
Lift/Tilt Lockout Valve and Test………………………………………………………………………………………………………………….294
Fan/Power-A-Tach/Differential Lock Valve Tests……………………………………………………………………………………………………..296
Power-A-Tach/Quick Attachment Lock Solenoids Test……………………………………………………………………………………………….297
Hydraulic Fan Solenoids………………………………………………………………………………………………………………………298
Differential Lock Solenoid Test……………………………………………………………………………………………………………….298
Hydraglide…………………………………………………………………………………………………………………………………………300
Hydraglide™ Ride Control Solenoid Test…………………………………………………………………………………………………………….302
Solenoid Valve Disassembly/ Reassembly………………………………………………………………………………………………………………..303
Steering…………………………………………………………………………………………………………………………………………..304
Steering Priority Valve Test……………………………………………………………………………………………………………………..304
Hydraulic System Troubleshooting……………………………………………………………………………………………………………………..306
Hydraulic Schematics……………………………………………………………………………………………………………………………………309
Hydraulic Schematic — Standard (Non-Telescopic Machines)………………………………………………………………………………………………..309
Hydraulic Schematic — with High-Flow/2nd Auxiliary Hydraulics and Hydraglide (Non-Telescopic Machines)……………………………………………………….310
Hydraulic Schematic — Standard Auxiliary Hydraulics (Telescopic Machines)…………………………………………………………………………………311
Hydraulic Schematic – Standard Hydraulics with Options (Telescopic Machines)………………………………………………………………………………312
Hydraulic Schematic – High-Flow Auxiliary Hydraulics (Telescopic Machines)………………………………………………………………………………..313
Hydraulic Schematic – High-Flow Auxiliary Hydraulics with Options (Telescopic Machines)…………………………………………………………………….314
Electrical Control System……………………………………………………………………………………………………………………………….315
Electrical Control System General Information………………………………………………………………………………………………………….315
CAN System General Information……………………………………………………………………………………………………………………315
Control Modules…………………………………………………………………………………………………………………………………….316
Machine Control Unit (MCU)……………………………………………………………………………………………………………………….316
Transmission Control Unit (TCU)…………………………………………………………………………………………………………………..316
Engine Control Unit (ECU)………………………………………………………………………………………………………………………..316
Display/Indicators/Controls………………………………………………………………………………………………………………………317
Multi-Function Display……………………………………………………………………………………………………………………….317
Keypad……………………………………………………………………………………………………………………………………..317
Switch Panel………………………………………………………………………………………………………………………………..317
Multi-Function Joystick………………………………………………………………………………………………………………………317
Control Lever (Option)……………………………………………………………………………………………………………………….318
CAN System Service/Computer Connection………………………………………………………………………………………………………………..319
J1939 Data Connector…………………………………………………………………………………………………………………………….319
CAN/Computer Connection Harnesses…………………………………………………………………………………………………………………319
Service Adapter Harness………………………………………………………………………………………………………………………319
Yanmar Engine Connection Harness………………………………………………………………………………………………………………319
MCU/TCU Data Connection Harness……………………………………………………………………………………………………………….319
Multi-Function Display Data Connection Harness………………………………………………………………………………………………….320
Deutz Engine CAN/Computer Connection Harness (SerDia)……………………………………………………………………………………………….320
Danfoss Service Tool (Plus+1) Software…………………………………………………………………………………………………………….321
Multi-Function Display Service Software Update/Pass Code Reset……………………………………………………………………………………….321
Operation/Controller Area Network (CAN) Functional Organization………………………………………………………………………………………….322
Operation/CAN Function Organization Overview……………………………………………………………………………………………………….322
Keypad Input/Output Detail……………………………………………………………………………………………………………………….323
Display Output Detail……………………………………………………………………………………………………………………………324
Machine Control Unit (MCU) Input/Output Detail……………………………………………………………………………………………………..325
Travel Control Unit (TCU) Input/Output Detail………………………………………………………………………………………………………327
HydralocTM (Safety Interlock) Functional Detail…………………………………………………………………………………………………….328
Ignition/Starting Functional Detail……………………………………………………………………………………………………………….329
Operation Functional Detail………………………………………………………………………………………………………………………331
Load Arm Functional Detail……………………………………………………………………………………………………………………….332
Drive System Functional Detail……………………………………………………………………………………………………………………333
Auxiliary Hydraulics Functional Detail…………………………………………………………………………………………………………….337
Cooling Fan Functional Detail…………………………………………………………………………………………………………………….339
Warning Indicators Functional Detail………………………………………………………………………………………………………………340
Lighting Functional Detail……………………………………………………………………………………………………………………….342
Accessories and Options Functional Detail……………………………………………………………………………………………………………..344
CAN/Control System Troubleshooting……………………………………………………………………………………………………………………346
Inputs/Outputs Detail……………………………………………………………………………………………………………………………346
Error Codes…………………………………………………………………………………………………………………………………….372
MCU and Keypad CAN Error Codes……………………………………………………………………………………………………………………372
Electrical System………………………………………………………………………………………………………………………………………375
Power Distribution………………………………………………………………………………………………………………………………….383
Fuses/Relays……………………………………………………………………………………………………………………………………383
Power Distribution Module Fuse Socket Test…………………………………………………………………………………………………………383
Main Power Relay………………………………………………………………………………………………………………………………..383
Front Wiper Relay……………………………………………………………………………………………………………………………….383
Relay Testing…………………………………………………………………………………………………………………………………..384
Machine Test………………………………………………………………………………………………………………………………..384
Bench Test………………………………………………………………………………………………………………………………….384
Start/Glow Relay Solenoid Test……………………………………………………………………………………………………………………….385
Control Modules…………………………………………………………………………………………………………………………………….385
J1939 Data Connector………………………………………………………………………………………………………………………………..386
Easy Manager……………………………………………………………………………………………………………………………………….386
Easy Manager Fuse……………………………………………………………………………………………………………………………….386
Easy Manager Relay………………………………………………………………………………………………………………………………387
Wire Harness Diagrams…………………………………………………………………………………………………………………………………..389
Wire Harness Diagram — Front Chassis…………………………………………………………………………………………………………………389
Wire Harness Diagram — Rear Chassis — AL750 (SN J00070227 and Down), AL708 (SN A00075299 and Down), AL650 (SN C00060321 and Down), AL608 (SN C00065301 and Down)….390
Wire Harness Diagram — Telescopic Load Arm……………………………………………………………………………………………………………392
Wire Harness Diagram — Cab/Canopy……………………………………………………………………………………………………………………393
Wire Harness Diagram — Engine — AL650 (SN C00060322 and Up), AL608 (SN C00065302 and Up), MLA-6……………………………………………………………394
Wire Harness Diagram — Engine — AL650 (SN C00060321 and Down), AL608 (SN C00065301 and Down)………………………………………………………………395
Wire Harness Diagram — 700 Series / MLA-7 / MLA-T Engine……………………………………………………………………………………………….396
Electrical Schematics…………………………………………………………………………………………………………………………………..397
Electrical Schematic – Chassis (1 of 3)……………………………………………………………………………………………………………….397
Electrical Schematic – Chassis (2 of 3)……………………………………………………………………………………………………………….398
Electrical Schematic – Chassis – Switch Panel Splices (3 of 3)…………………………………………………………………………………………..399
Electrical Schematic – Chassis – Rear Frame (1 of 2)……………………………………………………………………………………………………400
Electrical Schematic – Chassis – Rear Frame (2 of 2)……………………………………………………………………………………………………401
Electrical Schematic – Chassis – Front Frame/Headlights (Non-Telescopic Machines)………………………………………………………………………….402
Electrical Schematic – Chassis – Front Frame/Headlights (Telescopic Machines) (1 of 2)……………………………………………………………………..403
Electrical Schematic – Chassis – Front Frame/Headlights (Telescopic Machines) (2 of 2)……………………………………………………………………..404
Electrical Schematic – Enclosed ROPS/FOPS……………………………………………………………………………………………………………..405
Electrical Schematic – HVAC………………………………………………………………………………………………………………………….406
Electrical Schematic – Open ROPS/FOPS…………………………………………………………………………………………………………………407
Electrical Schematic – 600 Series Engine (Yanmar 4TNV98CT-PGWLT)…………………………………………………………………………………………408
Electrical Schematic — 700 Series Engine (Deutz TD3.6L4) (1 of 2)………………………………………………………………………………………..409
Electrical Schematic — 700 Series Engine (Deutz TD3.6L4) (2 of 2)……………………………………………………………………………………….410
Electrical Schematic — Electrical Auxiliary Circuits……………………………………………………………………………………………………411
Electrical Schematic — Rear Lights Connection…………………………………………………………………………………………………………412
Electrical Schematic — 14-Pin Auxiliary Circuit………………………………………………………………………………………………………..413
Electrical Schematic — Turn Signal/Radio Jumpers………………………………………………………………………………………………………414
Chassis……………………………………………………………………………………………………………………………………………….415
Chassis General Information………………………………………………………………………………………………………………………….415
Cab/Canopy Removal………………………………………………………………………………………………………………………………….415
Cab/Canopy Installation……………………………………………………………………………………………………………………………..421
Engine Cover Removal/Replacement……………………………………………………………………………………………………………………..427
Engine Cover Removal…………………………………………………………………………………………………………………………….427
Engine Cover Replacement…………………………………………………………………………………………………………………………428
Articulation Joint………………………………………………………………………………………………………………………………….429
Articulation Joint Disassembly (Telescopic Machines)………………………………………………………………………………………………..430
Articulation Joint Assembly (Telescopic Machines)…………………………………………………………………………………………………..440
Articulation Joint Disassembly (Non- Telescopic Machines)……………………………………………………………………………………………456
Articulation Joint Assembly (Non-Telescopic Machines)……………………………………………………………………………………………….465
Telescopic Load Arm…………………………………………………………………………………………………………………………………….475
Telescopic Load Arm Component Identification…………………………………………………………………………………………………………..475
Load Arm Extend, Lift, and Slave Cylinders…………………………………………………………………………………………………………476
Outer Load Arm and Hose Support…………………………………………………………………………………………………………………..477
Inner Load Arm and Tilt Cylinder………………………………………………………………………………………………………………….478
Pivot Link……………………………………………………………………………………………………………………………………..479
Load Arm Hydraulics (1 of 3)……………………………………………………………………………………………………………………..480
Load Arm Hydraulics (2 of 3)……………………………………………………………………………………………………………………..481
Load Arm Hydraulics (3 of 3)……………………………………………………………………………………………………………………..482
Tilt Cylinder Removal/Installation……………………………………………………………………………………………………………………483
Tilt Cylinder Removal……………………………………………………………………………………………………………………………483
Tilt Cylinder Installation……………………………………………………………………………………………………………………….488
Inner Load Arm Hydraulic Tube and Hose Removal/Installation……………………………………………………………………………………………..492
Load Arm Hydraulic Tube and Hose Removal…………………………………………………………………………………………………………..492
Inner Load Arm Hydraulic Tube and Hose Installation…………………………………………………………………………………………………499
Load Arm Slide Pad Service…………………………………………………………………………………………………………………………..504
Load Arm Slide Pad Inspection/Shims……………………………………………………………………………………………………………….505
Front Slide Pad Inspection……………………………………………………………………………………………………………………505
Rear Slide Pad Inspection…………………………………………………………………………………………………………………….506
Front Slide Pad Replacement………………………………………………………………………………………………………………………507
Front Side Slide Pad Replacement………………………………………………………………………………………………………………507
Front Top/Bottom Slide Pad Replacement…………………………………………………………………………………………………………508
Rear Slide Pad Replacement……………………………………………………………………………………………………………………….508
Rear Side Slide Pad Replacement……………………………………………………………………………………………………………….509
Rear Top/Bottom Slide Pad Replacement………………………………………………………………………………………………………….509
Rear Slide Pad Replacement Completion………………………………………………………………………………………………………….510
Hose Support Removal………………………………………………………………………………………………………………………………..510
Hose Support Installation……………………………………………………………………………………………………………………………513
Extension Indicator Potentiometer (Domestic Telescopic Machines)…………………………………………………………………………………………517
Extension Indicator Potentiometer Description………………………………………………………………………………………………………518
Extension Potentiometer Removal…………………………………………………………………………………………………………………..518
Extension Potentiometer Installation………………………………………………………………………………………………………………519
Extension Indicator Potentiometer Calibration (Domestic Telescopic Machines Only)………………………………………………………………………520
HVAC System……………………………………………………………………………………………………………………………………………523
Air Conditioning Refrigerant Recovery…………………………………………………………………………………………………………………528
Air Conditioning System Port Access……………………………………………………………………………………………………………….528
Air Conditioning System Charging……………………………………………………………………………………………………………………..528
700 Series / MLA-7 / MLA-T Air Conditioning Compressor Removal…………………………………………………………………………………………..529
700 Series / MLA-7 / MLA-T Air Conditioning Compressor Installation………………………………………………………………………………………530
600 Series / MLA-6 Engine……………………………………………………………………………………………………………………………….533
600 Series / MLA-6 Engine Removal…………………………………………………………………………………………………………………….533
600 Series / MLA-6 Engine Installation………………………………………………………………………………………………………………..542
700 Series / MLA-7 / MLA-T Engine………………………………………………………………………………………………………………………..551
700 Series / MLA-7 / MLA-T Engine Removal……………………………………………………………………………………………………………..551
700 Series / MLA-7 / MLA-T Engine Installation…………………………………………………………………………………………………………561
Engine Cooling System…………………………………………………………………………………………………………………………………..571
Engine Cooling System General Information……………………………………………………………………………………………………………..571
Cooling Fan Operation……………………………………………………………………………………………………………………………571
Cooling Fan Reversal…………………………………………………………………………………………………………………………572
600 Series / MLA-6 Radiator Removal…………………………………………………………………………………………………………………..575
600 Series / MLA-6 Radiator Installation………………………………………………………………………………………………………………579
700 Series / MLA-7 / MLA-T Radiator Removal……………………………………………………………………………………………………………583
700 Series / MLA-7 / MLA-T Radiator Installation……………………………………………………………………………………………………….588
Troubleshooting………………………………………………………………………………………………………………………………………..593
Engine Troubleshooting………………………………………………………………………………………………………………………………593
Indicator Lamp Troubleshooting……………………………………………………………………………………………………………………….594
Seal and Hose Troubleshooting………………………………………………………………………………………………………………………..595
Hydraulic System Troubleshooting……………………………………………………………………………………………………………………..596
Hydrostatic Travel Drive System Troubleshooting………………………………………………………………………………………………………..596
Electrical Troubleshooting…………………………………………………………………………………………………………………………..596
Electrical Inputs/Outputs………………………………………………………………………………………………………………………..597
Error Codes………………………………………………………………………………………………………………………………………..597
MCU and Keypad CAN Error Codes……………………………………………………………………………………………………………………597
Yanmar Engine Diagnostic Trouble Codes (DTC)……………………………………………………………………………………………………….599
Deutz Engine Diagnostic Trouble Codes (DTC)………………………………………………………………………………………………………..606
Specifications…………………………………………………………………………………………………………………………………………625
Fluids/Lubricants Types and Capacities………………………………………………………………………………………………………………..625
Payloads/Capacities…………………………………………………………………………………………………………………………………627
Non-Telescopic Machines………………………………………………………………………………………………………………………….627
Telescopic Machines……………………………………………………………………………………………………………………………..628
Pallet Fork Capacities Load Chart – Domestic (Telescopic Machines)………………………………………………………………………………..629
Pallet Fork Capacities Load Chart – EU (Telescopic Machines)……………………………………………………………………………………..630
Dimensions…………………………………………………………………………………………………………………………………………631
Non-Telescopic Machines………………………………………………………………………………………………………………………….631
Telescopic Machines……………………………………………………………………………………………………………………………..633
Weights……………………………………………………………………………………………………………………………………………635
Coolant Compound Table………………………………………………………………………………………………………………………………635
Wheels/Tires……………………………………………………………………………………………………………………………………….636
Engine…………………………………………………………………………………………………………………………………………….636
Hydraulic System……………………………………………………………………………………………………………………………………637
Drive Hydraulics………………………………………………………………………………………………………………………………..637
Work Hydraulics…………………………………………………………………………………………………………………………………637
Sound Power/Pressure Levels (Non-Telescopic Machines)…………………………………………………………………………………………………..637
Sound Power/Pressure Levels (Telescopic Machines)………………………………………………………………………………………………………637
Vibration Levels……………………………………………………………………………………………………………………………………638
Common Materials and Densities……………………………………………………………………………………………………………………….639
Index…………………………………………………………………………………………………………………………………………………641
Torque Specifications…………………………………………………………………………………………………………………………………..647